Optimize High-Energy Pumps With Improved Impeller Design

Posted on September 15, 2016

As new design and manufacturing technologies are developed, end users can affordably upgrade their systems and verify better performance.

Written by: Bob Jennings & Dr. Gary Dyson (Hydro, Inc.)
Publisher: Pumps & Systems / August 2015

The rising cost of electrical power has caused many industrial plants to shift their focus to energy consumption. Plants often run pumping equipment continuously, and much research has pointed to opportunities for cost savings by optimizing pumping equipment.

When evaluating the potential for energy savings, end users cannot consider a pump in isolation. The suitability of the pump for the system within which it operates is vital. Even the best designed and most efficient equipment offers power-saving potential if it is run off its best efficiency point (BEP) in a system for which it is ill-applied.

Image 1. Much research has pointed to opportunities for cost savings by optimizing pumping equipment. (Images and graphics courtesy of Hydro, Inc.)

Many plants have been in operation for more than 40 years, and their operating philosophies have changed over time. Plant improvements have enabled higher throughput, often increasing production by as much as 125-150 percent. Unfortunately, little is done to improve or increase the performance of the support-service pumping equipment, such as cooling water pumps.

As system flow demands increase, the duty point of the pumps is forced to shift far to the right of the BEP, well outside the acceptable operating range (AOR). This causes efficiency and pump reliability to decrease dramatically.

Casting tolerances, surface finishes, and impeller/volute or impeller/diffuser geometry have all dramatically improved during the last 40 years. But because many pumps were installed when the plants were commissioned, the existing pumps were manufactured using techniques that would be considered obsolete today. The result is higher energy costs and reduced reliability and availability, which often cause production delays. Continue reading →

10 Key Facts About Reciprocating Pumps

Posted on September 15, 2016

This pump type’s unique system design requirements are often ignored or misapplied, which affects reliability and operation.

Written by: Gary Dyson and Herb Tackett Jr. (Hydro, Inc.)
Publisher: Pumps & Systems / July 2015

Because Centrifugal pumps are widely used, pump and rotating equipment engineers are generally familiar with this equipment’s operating principles, performance curves and selection criteria.

Image 1. While centrifugal pumps are the subject of much training, the dwindling population of reciprocating pumps has led to a loss of understanding of this pump type’s unique system design requirements. (Images and graphics courtesy of Hydro, Inc.)

While Centrifugal pumps are the subject of much training, the dwindling population of reciprocating pumps has led to a loss of understanding of this pump type’s unique system design requirements. Centrifugal pump specifications are now commonly and incorrectly applied to reciprocating pumps, which can lead to significant reliability problems.

End users should consider these 10 key facts about reciprocating pumps that can influence reliability and operation. Continue reading →

Hydro’s Test Lab is the first to be certified by the Hydraulic Institute (HI) Pump Test Lab Approval Program

Posted on September 10, 2015

screen-shot-2016-09-23-at-4-49-50-pm We are very pleased to announce that Hydro’s Test Lab is the first test lab to be certified by the Hydraulic Institute in their new pump test approval program.

The Hydraulic Institute which will celebrate 100 years of industry leadership in 2016 is a prestigious organization which develops and delivers comprehensive industry standards and educational programs.

Special thanks to Hydro’s Jeff Johnson, General Manager of the Test Lab and Ares Panagoulias Test Lab Engineer whose dedicated efforts in working with the accreditation team were critical to the approval of our test lab.

Learn more via Pumps & Systems

Hydro is pleased to introduce Hydro Richards

Posted on June 22, 2015

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Hydro, Inc. is pleased to introduce Hydro Richards, its newest service location in Canada. The facility is located in Port Coquitlam and is conveniently located close to the TransCanada Highway, US Border and Vancouver International Airport. Hydro Richards specializes in pump repairs and has extensive experience in the manufacture of machined pump parts and babbitted bearings, with shafts being a solid area of expertise. They also provide special overlays and coatings to increase component life. Hydro Inc has added its complete array of pump services to strengthen their product and service offerings in the Pacific Northwest.

For more information regarding the services and capabilities of Hydro Richards, please visit our website at: www.hydrorichards.com

New 3-D Casting Methods Produce Spare Parts Faster

Posted on March 2, 2015

Additive manufacturing also improves geometric tolerances.

Written by: Jesse Stinson (Hydro Parts Solutions) & Werner Barnard (Hydro Inc.)
Publisher: Pumps & Systems / March 2, 2015

An increasing number of industrial plants are reducing the spare parts inventories stored at their facilities. At the same time, they are replacing fewer pumps because of capital constraints and have determined that remanufacturing existing equipment is the best path forward. Many of the pumps within these facilities have exceeded 50 years of service. This drives the need for replacement parts and, in some cases, emergency replacement parts. Considering the age of these pumps, the replacement parts from the manufacturer are likely obsolete and may not be easily available. Further complicating the situation is the location of manufacture. Many cast parts are manufactured outside the U.S and have long lead times.

To address these challenges, many companies are developing technologies to meet the specific and growing demands of the industry. Many of these advanced tools, including coordinate measure machine (CMM) technology, allow for quicker emergency repairs, faster deliveries and higher quality pump parts.

Image 1. New bronze impeller casting (Images and graphics courtesy of Hydro Inc.)

Figure 1. Reverse engineering raw scan data

Emergency equipment repairs are common throughout the industry. Having fewer spare parts makes this classification of repair more challenging. Standard equipment repairs typically take six to eight weeks, while emergency repairs must be completed within one day to three weeks, depending on the severity of the situation.

This type of repair often drives the need for rapidly supplied cast parts, which traditionally require long lead times because of the use of wooden tooling to create the mold to manufacture the casting.

Recent advancements in 3-D technology, known as additive manufacturing, allow the cast parts manufacturer to meet customer demands by eliminating the need to create traditional tooling.

Continue reading →